U.S. patent application number 12/713221 was filed with the patent office on 2010-06-17 for resilient floor tile and method of making same.
This patent application is currently assigned to CONGLEUM CORPORATION. Invention is credited to Robert Dempsey, Donald C. Ferguson, Andrei Sharygin, Richard Whitehouse.
Application Number | 20100146895 12/713221 |
Document ID | / |
Family ID | 33310252 |
Filed Date | 2010-06-17 |
United States Patent
Application |
20100146895 |
Kind Code |
A1 |
Dempsey; Robert ; et
al. |
June 17, 2010 |
RESILIENT FLOOR TILE AND METHOD OF MAKING SAME
Abstract
A resilient floor tile is described that comprises a base; a
protective film layer; and a decorative layer disposed between the
base and the protective film layer; wherein the resilient floor
tile has a top surface and a convex edge along a perimeter of the
top surface. In another embodiment, the resilient floor tile
comprises a decorative layer comprising a printed ink forming a
decorative pattern disposed between a base and a protective film
layer; wherein the decorative pattern extends over at least a
portion of a contoured edge of the tile such that the decorative
pattern is substantially undistorted. The process for making a
resilient floor tile comprises preheating a printed tile blank;
cutting and molding the printed tile blank concurrently to form a
resilient floor tile having a convex edge along a top, outer
perimeter of the resilient floor tile.
Inventors: |
Dempsey; Robert;
(Flemington, NJ) ; Ferguson; Donald C.;
(Bordentown, NJ) ; Sharygin; Andrei; (Columbus,
NJ) ; Whitehouse; Richard; (Yardville, NJ) |
Correspondence
Address: |
CHOATE, HALL & STEWART LLP
TWO INTERNATIONAL PLACE
BOSTON
MA
02110
US
|
Assignee: |
CONGLEUM CORPORATION
Mercerville
NJ
|
Family ID: |
33310252 |
Appl. No.: |
12/713221 |
Filed: |
February 26, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12417082 |
Apr 2, 2009 |
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12713221 |
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10427778 |
Apr 30, 2003 |
7550192 |
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12417082 |
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Current U.S.
Class: |
52/391 ;
428/192 |
Current CPC
Class: |
Y10T 428/24752 20150115;
B32B 27/30 20130101; B29C 2793/0009 20130101; B29L 2031/104
20130101; B32B 2307/75 20130101; Y10T 428/24777 20150115; B32B
27/304 20130101; B26F 1/40 20130101; B44C 5/0446 20130101; E04F
15/02016 20130101; B32B 2255/26 20130101; Y10T 428/24802 20150115;
B29L 2009/00 20130101; Y10T 428/24876 20150115; Y10T 428/24521
20150115; Y10T 428/24942 20150115; B32B 27/20 20130101; B32B
2255/10 20130101; B29C 67/0044 20130101; B32B 2419/04 20130101;
E04F 15/02 20130101; E04F 15/10 20130101 |
Class at
Publication: |
52/391 ;
428/192 |
International
Class: |
E04F 15/022 20060101
E04F015/022; B32B 3/02 20060101 B32B003/02 |
Claims
1-45. (canceled)
46. A resilient floor tile, dimensioned and constructed for
grouting comprising: a base comprising an organic polymer present
at a level less than 34% by weight of the base, so that the tile
has rigidity; and a decorative layer, wherein the base and the
decorative layer together form a resilient floor tile having: a top
surface with a contoured edge along its perimeter, which contoured
edge has an outermost contoured surface, and a bottom surface, a
vertical sidewall extending from the bottom surface of the tile to
the outermost contoured surface, wherein the decorative layer
extends over at least a portion of the contoured edge, and wherein
the tile is constructed such that when the tile is grouted, the top
level of the grout is below the top surface of the tile and the
contoured edge extends above the top surface of the grout, so that
there is no exposed edges where the outermost contoured edge meets
the tile sidewall.
47. The resilient floor tile of claim 46, wherein the organic
polymer is a vinyl polymer.
48. The resilient floor tile of claim 46, wherein the outermost
contoured edge extends at least halfway down the tile sidewall,
from the tile's top surface.
49. The resilient floor tile of claim 46, wherein the outermost
contoured edge extends at least 25% of the height of the tile, down
the tile sidewall, from the tile's top surface.
50. The resilient floor tile of claim 46, wherein the outermost
contoured edge extends at least 75% of the height of the tile, down
the tile sidewall, from the tile's top surface.
51. The resilient floor tile of claim 46, wherein the outermost
contoured edge extends at least 10% of the height of the tile, down
the tile sidewall, from the tile's top surface.
52. The resilient floor tile of claim 46, wherein the wherein the
sidewall is substantially free from cracks and small holes.
53. The resilient floor tile of claim 46, wherein the decorative
layer extends over the entire outermost contoured surface.
54. The resilient floor tile of claim 46, wherein the decorative
layer extends over the entire contoured edge.
55. The resilient floor tile of claim 46, wherein the vertical side
wall is substantially solid in that it does not have preformed
openings or openings of predetermined shapes or sizes.
56. The resilient floor tile of claim 46, wherein the base further
comprises one or more plasticizers.
57. The resilient floor tile of claim 46, wherein the base further
comprises one or more pigments.
58. The resilient floor tile of claim 46, wherein the base is
approximately 50-200 mils thick.
59. The resilient floor tile of claim 46, wherein the tile has a
thickness of approximately 4 mm.
60. A resilient floor tile, dimensioned and constructed for
grouting comprising: a base comprising organic polymer present at a
level less than 34% by weight of the base, so that the tile has
rigidity; and a decorative layer, wherein the base, and the
decorative layer together form a resilient floor tile having: a top
surface with a convex edge along its perimeter, which convex edge
has an outermost convex surface, and a bottom surface, a vertical
sidewall extending from the bottom surface of the tile to the
outermost convex surface, wherein the decorative layer extends over
at least a portion of the convex edge, and wherein the tile is
constructed such that when the tile is grouted, the top level of
the grout is below the top surface of the tile and the convex edge
extends above the top surface of the grout, so that there is no
exposed edges where the outermost convex edge meets the tile
sidewall.
61. The resilient floor tile of claim 60, wherein the polymer is a
vinyl polymer.
62. The resilient floor tile of claim 60, wherein the outermost
convex edge extends at least halfway down the tile sidewall, from
the tile's top surface.
63. The resilient floor tile of claim 60, wherein the outermost
convex edge extends at least 25% of the height of the tile, down
the tile sidewall, from the tile's top surface.
64. The resilient floor tile of claim 60, wherein the outermost
convex edge extends at least 75% of the height of the tile, down
the tile sidewall, from the tile's top surface.
65. The resilient floor tile of claim 60, wherein the outermost
convex edge extends at least 10% of the height of the tile, down
the tile sidewall, from the tile's top surface.
66. The resilient floor tile of claim 60, wherein the sidewall is
substantially free from cracks and small holes.
67. The resilient floor tile of claim 60, wherein the decorative
layer extends over the entire outermost convex surface.
68. The resilient floor tile of claim 60, wherein the decorative
layer extends over the entire convex edge.
69. The resilient floor tile of claim 60, wherein the vertical side
wall is substantially solid in that it does not have preformed
openings or openings of predetermined shapes or sizes.
70. The resilient floor tile of claim 60, wherein the base further
comprises one or more plasticizers.
71. The resilient floor tile of claim 60, wherein the base further
comprises one or more pigments.
72. The resilient floor tile of claim 60, wherein the base is
approximately 50-200 mils thick.
73. The resilient floor tile of claim 60, wherein the tile has a
thickness of approximately 4 mm.
74. A flooring comprising a plurality of tiles of claim 46
positioned adjacent to each other.
75. The flooring of claim 74 further comprising grout disposed
between the tiles.
76. The flooring of claim 75 wherein the top surface of the grout
is below the top surface of the tile and the contoured edge extends
above the top surface of the grout, so that there is no exposed
edges where the outermost contoured edge meets the tile
sidewall.
77. The flooring of claim 74, wherein the tiles are butt fit
against each other.
78. A flooring comprising a plurality of tiles of claim 60
positioned adjacent to each other.
79. The flooring of claim 78 further comprising grout disposed
between the tiles.
80. The flooring of claim 79 wherein the top surface of the grout
is below the top surface of the tile and the contoured edge extends
above the top surface of the grout, so that there is no exposed
edges where the outermost contoured edge meets the tile
sidewall.
81. The flooring of claim 78, wherein the tiles are butt fit
against each other.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to floor tiles. More
specifically, the invention is directed to a resilient floor tile
having a contoured edge and a method for making the same.
[0003] 2. Description of Related Art
[0004] Resilient floor coverings are produced in the form of a
continuous sheet or in the form of a tile, such as a vinyl
composition tile. Typically, resilient floor tiles are installed in
a butt-fit arrangement, wherein the side of each tile is in
physical contact with the sides of adjacent tiles. The tiles are
secured to the subfloor through the use of an adhesive; however,
there is typically no filler or adhesive used between the adjoining
sides of the tiles. As such, one disadvantage of this type of
installation is the presence of gaps or openings at tile joints,
which may result from an uneven cut along the side of a particular
tile during manufacture, an uneven subfloor or thermal contraction
of the tiles. Another disadvantage of this type of tile and
installation is maintaining each tile at the same height on the
floor as the tiles adjacent to it. If one tile is slightly higher
than an adjacent tile, a "step" is created between these tiles,
which may result in chipping or breakage of the tile portion that
is higher than the surface of the adjacent tile. In addition, the
side of the tile that extends above the adjacent tile surface may
also act to trap dirt along that side, which is typically difficult
to remove.
[0005] Regardless, attempts have been made to manufacture and
install resilient floor tiles to simulate the appearance of ceramic
tiles or natural tiles, such as stone tiles, including marble,
slate and granite, all of which are typically more expensive than a
resilient tile floor. For example, resilient tiles may contain a
decorative ink pattern to simulate the surface appearance of
ceramic or natural tiles, or they may contain other decorative
elements, such as small particles, to similarly simulate the
appearance of ceramic or natural tiles. Additionally, some
resilient tiles are embossed to simulate the grout that is used
between ceramic and natural tiles when installed as a flooring.
However, these attempts have never quite matched the appearance of
a ceramic or natural tile nor the appearance of a flooring having
grout between such ceramic or natural tiles.
[0006] One might consider installing existing resilient floor tiles
with grout; however, there are several disadvantages to this due
mainly to the square edge of the resilient floor tile. First, the
square edge would make it difficult to properly place the grout
between the tiles so that the grout does not pull out as additional
grout is laid. Second, grout will typically shrink in size such
that the top of the grout would be below the top surface of
adjacent tiles, making the exposed vertical edge of the tile more
susceptible to damage and collection of dirt along this edge. Also,
particles may be dislodged from this edge by foot traffic and
dragged across the top surface of the tile, thereby abrading,
marring or scuffing its surface.
[0007] Some resilient floor tiles have been made with a beveled or
flat, slanted edge. However, in these cases, when the beveled
portion is cut, the underlying substrate is exposed, which requires
additional processing to cover it up. For example, a paint or
coating must be applied to cover this exposed area, which may be a
different color from the top surface, thereby failing to simulate a
natural stone or ceramic tile appearance, which has a consistent
color across its surface. While these tiles are typically installed
in a butt-fit arrangement, if grout were used the flat surface of
this beveled portion will most likely result in the same difficulty
in installing the grout as with a square-edged tile since the edge
where the beveled portion meets the vertical side wall of the tile
will still be a sharp edge.
[0008] Therefore, there is a need for a resilient floor tile that
in use more closely simulates the appearance of a ceramic or
natural tile and that can allow for installation using grout.
SUMMARY OF THE INVENTION
[0009] A resilient floor tile and method for making the same are
described. In one embodiment, the resilient floor tile comprises a
base; a protective film layer; and a decorative layer disposed
between the base and the protective film layer; wherein the base,
the protective film layer and the decorative layer form a resilient
floor tile having a top surface and a convex edge along a perimeter
of the top surface. In another embodiment, the resilient floor tile
comprises a base; a protective film layer; and a decorative layer
comprising a printed ink forming a decorative pattern disposed
between the base and the protective film layer; wherein the base,
the protective film layer and the decorative layer form a resilient
floor tile having a top surface and a contoured edge along a
perimeter of the top surface and wherein the decorative layer
extends over at least a portion of the contoured edge such that the
decorative pattern is substantially undistorted.
[0010] The process for making the resilient floor tile comprises
preheating a printed tile blank; cutting the printed tile blank;
and molding the printed tile blank to form a convex edge along a
top, outer perimeter of the printed tile blank; wherein the cutting
and molding are performed concurrently to form a resilient floor
tile.
[0011] The convex edge of the present invention provides for an
surprisingly pleasing simulation of ceramic and natural tile
floors, such as stone tile floors, including, marble, slate and
granite. The convex or rounded edge allows for installation of the
resilient floor tile using grout, whereas tiles having a square
edge make grout installation difficult. In addition, a convex edge
allows for easier cleanability of the grout and the edge of the
tile itself, as compared to a tile having a right angle edge that
may have dirt embedded in the exposed vertical side. Further, the
print layer extends over the surface of the convex edge, thereby
alleviating the need to further print a decorative pattern on what
would otherwise be an exposed surface after cutting of a contoured
edge along the perimeter of the tile.
[0012] Other features of the invention will appear from the
following description in which the preferred embodiments are set
forth in detail in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1A is a cross-sectional view taken along line A-A of
FIG. 2 of a resilient floor tile according to one embodiment of the
present invention;
[0014] FIG. 1B is a cross-sectional view of a resilient floor tile
according to another embodiment of the present invention;
[0015] FIG. 2 is a top view of the resilient floor tile of FIG.
1A;
[0016] FIG. 3 is a partial plan view of a flooring made with
resilient floor tiles according to one embodiment of the present
invention;
[0017] FIG. 4 is a partial plan view of a press and die according
to one embodiment of the present invention;
[0018] FIG. 5 is a bottom view of an upper die plate according to
one embodiment of the present invention;
[0019] FIG. 6A is a partial plan view of a die at a first operating
position according to one embodiment of the present invention;
[0020] FIG. 6B is a partial plan view of the die of FIG. 6A at a
second operating position according to one embodiment of the
present invention; and
[0021] FIG. 7 is a process flow schematic of a process for making a
resilient floor tile according to one embodiment of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The structure and function of the preferred embodiments can
best be understood by reference to the drawings, which are
described below. It should be noted that where the same reference
designations appear in different figures, the numerals refer to the
same or corresponding structure in each of those locations.
[0023] FIG. 1A shows a cross-sectional view taken along line A-A of
FIG. 2 of a resilient floor tile according to one embodiment of the
present invention. Resilient floor tile 100 is a composite,
laminated structure that comprises a base 102, a decorative layer
104 disposed on top of the base 102, a protective film layer 106
disposed on top of the decorative layer 104, a top coat 108
disposed on top of the protective film layer 106, and a bottom coat
110 disposed on the bottom side of the base 102. The resilient
floor tile 100 also has a top surface 112 that, in use, is the
surface of the resilient floor tile 100 exposed to the environment
or foot traffic.
[0024] It should be appreciated that "resilient floor tile" refers
to those floor tiles that are synthetic or man-made and that have a
certain degree of resiliency or flexibility. Materials useful in
making a resilient floor tile may include organic materials, such
as polymeric materials, including, for example, vinyl or mixtures
of organic and inorganic materials. Accordingly, the base 102 may
be made of any material useful in making a resilient floor tile.
For example, the base may be a mixture of limestone and a polymeric
resin and may also include plasticizers and pigments. More
specifically, the polymeric resin may be a copolymer or a
homopolymer. Specific examples of base compositions include a vinyl
composition that includes limestone, acetate polyvinylchloride
resin, plasticizer and, optionally, pigments, where the organic
materials function as a binder for the limestone. Alternatively,
the base may be a vinyl composition that includes limestone,
polyvinylchloride homopolymer, plasticizer and, optionally,
pigments, where the organic materials also function as a binder for
the limestone.
[0025] It should be appreciated generally that the base contributes
significantly to the overall flexibility of the resilient floor
tile. Again, while any material may be used as the base, it is
preferred that the base composition and, therefore, the overall
resilient floor tile have some rigidity and not be completely
flexible such as a rubber tile or solid vinyl tile. Since the
binder content of the base affects the level of rigidity of the
overall resilient floor tile, it is preferred that the total
organic content or binder content of the base be less than
approximately 34% by weight, more preferably approximately 20% or
less by weight, approximately 18% or less by weight, or
approximately 17% or less by weight. Binder contents such as
approximately 26% by weight or approximately 28% by weight may also
be used.
[0026] While the base 102 is shown in FIG. 1A as having a
significantly greater thickness than the other layers of the
resilient tile 100, it should be appreciated that the thickness of
the base 102 may be any desired thickness, and the relative
dimensions shown in FIG. 1A are not intended to be limiting.
Preferably, however, the thickness of the base 102 is such that it
provides most of the structural rigidity to the resilient floor
tile 100. More preferably, the thickness of the base 102 is
approximately 50-200 mils. A preferred thickness for the entire
resilient floor tile 100 is approximately 4 mm.
[0027] The decorative layer 104 is disposed on top of the base 102.
The decorative layer 104 is any layer that provides a decorative
pattern or design to the resilient floor tile 100. In its simplest
form, the decorative layer may be a printed ink pattern that
provides a decorative pattern or design. Alternatively, the
decorative layer 104 may be a plurality of particles or chips of
various solid materials, such as wood, textiles, metals or plastics
that are disposed on top of or embedded in the top of the base 102.
Preferably such particles or chips will adequately adhere to the
base; however, an adhesive may be used if necessary. More
preferably, such particles or chips comprise polyvinylchloride
chips. It should be appreciated that the decorative layer may not
be a continuous layer that covers the entire top surface of the
base. For example, where the decorative layer comprises an ink
layer that forms a decorative pattern on the base, the ink itself
may not cover the entire top surface of the base, as it will only
be on those portions of the base required to make the decorative
pattern.
[0028] It should be appreciated that while the decorative layer 104
is shown in FIG. 1A as being disposed on top of the base 102, the
decorative layer may actually be disposed anywhere between the base
and any other layer in the resilient floor tile. For example, a
top-print film may be used (not shown). In this case, the
decorative layer would be an ink layer that provides a decorative
pattern or design that is printed on one side of a film, preferably
a polymeric film, such as polyvinylchloride. This top-print film is
placed on the base with the printed ink side facing up, such that
the film itself would be disposed directly on top of the base. In
this case, an additional film layer, the top-print film, would be
disposed between the base and the decorative layer or printed ink
layer. Typically, such top-print film has an approximate thickness
of 1.5-2 mils. Using a top-print film allows for the decorative
layer to be printed on the top-print film before being placed on
the base, which avoids having to print ink directly onto the base.
Such printing may be done through the use of transfer paper.
[0029] It should be appreciated that the relative thickness shown
in FIG. 1A for the decorative layer 104 is only for illustrative
purposes and should not be considered limiting. The decorative
layer 104 may be any desired thickness but in the case of printed
ink, it is preferably approximately 0.5 mils. Therefore, in
combination with a top-print film, the total thickness would be
approximately 2-2.5 mils.
[0030] The protective film layer 106 is a film that is disposed on
top of the decorative layer 104. The protective film layer 106 is
preferably a polymeric film and is used to protect the decorative
layer once the resilient floor tile 100 is placed in use. For
example, the protective film layer 106 may be used to protect the
decorative layer 104 from scuffing, marring and abrasion caused by
wear or foot traffic on the resilient tile 100.
[0031] The protective film layer 106 may be, for example, a cap
film, which is a polymeric film, such as a polyvinylchloride film.
Such a cap film may be disposed directly on top of a decorative
layer comprising either a printed ink decorative pattern or on top
of a decorative layer comprising a plurality of particles or chips
disposed on the base.
[0032] Alternatively, the protective film layer may be a back-print
film. A back-print film is a film having a printed ink pattern that
provides a decorative pattern or design on a bottom side of the
back-print film. This back-print film is positioned on top of the
base with the printed ink pattern facing the base of the tile. The
printed ink pattern then becomes the decorative layer of the
resilient floor tile, and the back-print film itself acts as the
protective layer to protect the printed ink or decorative layer
when the tile is used. This avoids the use of a separate protective
layer as would otherwise be used with a top-print film. Similar to
a top-print film, however, a back-print film allows for the
decorative layer to be disposed on the top-print film before being
placed on the base, which avoids having to print ink directly onto
the base.
[0033] It should be appreciated that the relative thickness shown
in FIG. 1A for the protective film layer 106 is only for
illustrative purposes and should not be considered limiting. The
cap film 106 may be any desired thickness but preferably is
approximately 3 mils.
[0034] It should be appreciated that the use of a protective film
layer is optional. In other words, a protective film layer, such as
a cap film or back-print film, is not required in the present
invention. In some embodiments of the present invention, the
protective film layer may be the top layer or exposed layer of the
resilient floor tile. In such cases, floors made using such
resilient tiles would typically require waxing to maintain the
appearance of the resilient tile.
[0035] The top coat 108 is disposed on top of the protective film
layer 106. Typically, the top coat 108 comprises a polymeric film,
such as a urethane film that is cured using ultraviolet radiation,
that is designed to protect the protective film layer 106 and the
decorative layer 104. In one embodiment, the top coat 108 is used
to avoid waxing of the resilient floor tile in use. In other words,
the use of a top coat generally makes the resilient tile a "no-wax"
floor tile. The top coat 108 may also comprise additional
components, such as particles, including, for example, aluminum
oxide or nylon particles, and it may have visible texture. Various
top coats that may be used in the present invention are described
in U.S. patent application Ser. No. 09/765,713, entitled "Coating
Having Macroscopic Texture and Process for Making Same," filed on
Jan. 19, 2001, which is incorporated herein by reference in its
entirety.
[0036] It should be appreciated that the top coat may also act as
the protective film layer, for example, in those cases where a top
coat, which may comprise a urethane film, is placed directly on the
decorative layer without the use of a separate protective film
layer. It should also be appreciated, however, that the use of the
top coat 108 is optional. Further, although not preferred, the
decorative layer may be exposed, which obviates the need for both a
protective film layer and a top coat.
[0037] Generally, any layer disposed on top of the decorative layer
104 may be used to protect the print layer. Such a protective layer
may alternatively be referred to as a "wear layer." Therefore, both
the protective film layer 106 and the top coat 108 may each be
referred to as a "wear layer" or may be collectively referred to as
a "composite wear layer."
[0038] The bottom coat 110 is any layer disposed on the bottom of
the base 102. Typically, the bottom coat 110 comprises a polymeric
film and is designed to maintain the integrity of the base 102 and
of the overall resilient floor tile 100, particularly upon
application of the other layers on top of the base 102. Application
of these other layers on top of the base 102 may result in stress
forces that tend to curl or pull the edges of the tile upwards. To
counter these forces, the bottom coat 110 may be used. It should be
appreciated, however, that use of the bottom coat 110 is
optional.
[0039] As shown in FIG. 1A, a novel aspect of the present invention
is the convex or rounded edge 114 of the resilient floor tile 100.
It should be appreciated that this convex edge 114 is located at
the top of the resilient tile 100, as opposed to the bottom, and
extends around the entire perimeter of the top surface 112 of the
resilient tile 100. It should be appreciated that reference to the
top surface of the resilient tile 100 refers simply to the top,
exposed surface of the tile, regardless of what layer is actually
on top. For example, the top surface could be the top of the
protective film layer or the top of the top coat, if present.
[0040] The convex edge 114 is also contiguous with the vertical
side wall 116 of the resilient floor tile 100, which is that
portion of the side of the resilient tile 100 that extends from the
convex edge 114 to the bottom of the resilient tile 100. In other
words, where the curvature of the convex edge 114 ends, the
vertical side wall 116 begins and continues to the bottom of the
resilient floor tile 100.
[0041] As will be discussed below, it should be appreciated that
this convex edge 114 is typically formed after the base 102, the
decorative layer 104 and the protective film layer 106 have been
put together. As a result, as shown in FIG. 1A, both the decorative
layer 104 and the protective film layer 106 extend over at least a
portion of the convex edge portion 114 and preferably over the
entire curvature of the convex edge 114. A further novel aspect of
the present invention is that the decorative pattern provided by
the decorative layer 104 that extends over the convex edge portion
is substantially undistorted. For example, in the embodiment where
the decorative layer comprises a printed ink that forms the
decorative pattern, this decorative pattern appears to have little
or no visible distortion as it extends over the convex edge
portion. In this manner, the decorative pattern remains visible and
visually pleasing on the top surface 112 as well as along the
convex edge 114 as it extends over the side of the resilient floor
tile 100.
[0042] It should be appreciated that the convex edge 114 may have
any arc or radius of curvature desired. In any case, the print
layer 104 and the cap film 106 will extend over at least a portion
of the convex edge 114, and, preferably, over the entire curvature
of the convex edge 114. In other words, with a curvature having a
larger radius or arc, the convex edge 114 will have a greater
surface area and will extend further towards the bottom of the
resilient floor tile before becoming integral with the vertical
side wall 116. In this case, it is preferred that the print layer
104 extend over this larger surface area of the convex edge 114 to
cover the entire surface area of the convex edge from the top
surface 112 to the point where it becomes integral to the vertical
side wall 116. Similarly, a smaller radius or arc would allow for a
smaller curved edge having a smaller surface area and a
correspondingly higher vertical side wall. It should be appreciated
that, generally, the layers on top of the print layer may extend
over the convex edge to a lesser extent than the underlying print
layer. It should also be appreciated that it is not necessary for
the print layer to extend over the entire surface area of the
convex edge. In other words, the print layer will extend along the
entire length of the edge or side of the resilient floor tile but
may only cover a portion of the convex edge from the top surface to
the point where it becomes integral to the vertical side wall.
[0043] It should further be appreciated that the convex edge 114 is
just one example of the type of edge that may be used on the tile.
The edge may include other contours or shapes, such as a flat,
beveled edge. Although a convex or rounded edge is more preferred
for use in installing the resilient floor tiles of the present
invention with grout, the decorative layer and decorative pattern
may still be disposed over an edge having other contours, such as a
beveled edge, so as to not distort the decorative pattern.
[0044] It should also be appreciated that the side wall 116 is
substantially solid, meaning that while it may have imperfections,
such as cracks or small holes, it does not have any pre-formed
openings or openings of predetermined shapes and sizes that may be
used for other purposes, for example, to accept interlocking male
portions from adjacent tiles. Further, the side wall 116 does not
have to be perfectly vertical or flat, particularly if the
resilient floor tile 100 is to be installed using grout. Such an
installation has the advantage of accommodating imperfectly-shaped
side walls.
[0045] FIG. 1B is a cross-sectional view of a resilient floor tile
according to another embodiment of the present invention. While
FIG. 1A has been described as having multiple layers on top of a
base, FIG. 1B illustrates another embodiment of the present
invention, which is a resilient floor tile 150 having only a base
152 with particles or chips 154 dispersed throughout that provide a
decorative effect on the top surface 156 of the tile 150. (Only a
few of the chips 154 are labeled in FIG. 1B.) These chips 154 may
be selected from various solid materials, such as wood, textiles,
metals or plastics, such as thermoplastic or thermoset polymers
including, for example, homopolymers or copolymers, specifically,
for example, vinyl acetate resins or polyvinylchloride, and may
have different colors ranging from white to dark. Further, the
number of chips 154 used may vary. While FIG. 1B illustrates a
resilient floor tile made using a significant number of chips such
that each chip is compressed against another chip, a much lower
concentration of chips 154 may be used. In this latter case,
obviously the base will contain a higher concentration of, for
example, limestone.
[0046] The resilient floor tile 150 has convex edges 158 that
extend around its perimeter at the top of the base 152. Similar to
the embodiment of FIG. 1A, it should be appreciated that any arc or
radius of curvature of the convex edges 158 may be used. Further,
it should be appreciated that the edge may include other contours
or shapes, such as a flat, beveled edge. The resilient floor tile
150 does not have any additional layers on top; however, it should
be appreciated that additional layers may be added. For example, a
protective film layer, such as a cap film, or a top film that acts
as a protective film layer, may be disposed on top of the base
152.
[0047] From the foregoing, it should be appreciated that any
resilient floor tile composition may be used in the present
invention. For example, resilient floor tiles known in the art,
such as any resilient floor tile base having polyvinylchloride, may
be used to provide a resilient floor tile having a contoured edge,
such as a rounded or convex edge. Further, any resilient floor tile
construction may be used in the present invention, including the
use of only a base, such as a base having particles or chips, or a
base having multiple layers thereon.
[0048] FIG. 2 is a top view of the resilient floor tile of FIG. 1A.
As shown in FIG. 2, the resilient floor tile 100 is square.
Further, it is evident from FIGS. 1 and 2 that the decorative layer
104, the cap film 106, the top coat 108 and the bottom coat 110 do
not extend beyond the perimeter or boundary of the base 102. In
other words, the horizontal dimensions of each layer are similar
and are aligned with the perimeter of the base 102. It should be
appreciated, however, that the resilient floor tile of the present
invention may be any shape, including, for example, round, oval,
rectangular, triangular, a polygon having any number of sides, or
any other shape. In these cases, each layer of the resilient floor
tile would have a substantially similar shape to every other layer,
except with respect to a decorative layer, which as described above
will generally take the shape of the desired decorative pattern and
may or may not be a continuous or complete layer across the entire
surface of the resilient floor tile. As shown, preferably, the
shape of the resilient tile of the present invention is square.
More preferably, the resilient tile of the present invention is
9''.times.9'', 12''.times.12'', 14''.times.14'', 16''.times.16'' or
18''.times.18''. It should be appreciated from FIG. 2 that the
corners of the resilient floor tile 100 are square, although it is
not necessary that the corners be square.
[0049] FIG. 3 is a partial plan view of a flooring made with
resilient floor tiles according to one embodiment of the present
invention. Specifically, FIG. 3 illustrates a flooring 300
installed using resilient floor tiles made according to the present
invention with grout. For illustrative purposes, only two resilient
floor tiles 100 are shown (individual layers of each tile are not
shown); however, an entire flooring would obviously be made using
any desired number of resilient tiles necessary to cover the
flooring area of interest and with any resilient floor tile made
according to the present invention. FIG. 3 shows the subfloor 302
and an adhesive layer 304 disposed between the bottom of each
resilient tile 100 and the subfloor 302. It should be appreciated
that any type of adhesive may be used, but, preferably, either a
pressure sensitive adhesive or a wet-set adhesive, or combination
thereof, is used. Grout 306 is installed between the adjacent
resilient floor tiles 100. As shown, the top level of the grout 306
is below the top surface 112 of each of the resilient floor tiles
100. The combination of the grout 306 being disposed below the top
surfaces 112 of each of the adjacent resilient floor tiles 112,
each having a convex edge 114, is what gives the flooring 300 the
appearance of a ceramic or natural tile floor, such as a stone,
marble, slate or granite.
[0050] It should be appreciated that the resilient floor tiles of
the present invention may also be installed in a butt-fit
arrangement, wherein each tile is positioned physically against an
adjacent tile. In this installation, grout would not be used;
however, the tiles would be adhered to the subfloor in the same
manner by using an adhesive such as a pressure sensitive adhesive
or a wet-set adhesive. A joint sealer may be used, however, to fill
any gaps or openings between adjacent tiles.
[0051] FIG. 4 is a partial plan view of a press and die according
to one embodiment of the present invention. In general, it should
be appreciated that one of skill in the art is familiar with such
presses and how they are constructed and operated. Generally, the
press 402 comprises a base 404 and an upper moveable portion 406
that can be moved in an up and down motion by a hydraulic cylinder
408 along guideposts 410. An upper die plate 412 is attached to the
upper movable portion 406, and a corresponding lower die plate 414
is attached to the base 404. A knife 416 is attached to the upper
die plate 412 about its perimeter. It should be appreciated that
FIG. 4 actually provides a cross-sectional view of the upper die
plate 412 to illustrate the curvature 420 of the upper die plate
412 and the cutting edge 420 of the knife 416. Therefore, as will
be discussed in connection with FIG. 5, the curvature 420 and the
knife 416 actually extend around the entire perimeter of the upper
die plate 412.
[0052] Also shown in FIG. 4 are scrap ejector plates 417, which are
each supported by springs 418. A representative resilient tile
blank 422 is also shown on top of the lower die plate 414. One of
skill in the art will appreciate that there are other components of
the press 402 that are not shown, such as a heater and temperature
control system that provide for heating either or both of the upper
die plate 412 and lower die plate 414 to a desired set point
temperature.
[0053] FIG. 5 is a bottom view of an upper die plate according to
one embodiment of the present invention. The upper die plate 500
comprises a center portion 502, which is generally a large block
made of metal, and four side portions 504 that are beveled and
connected at each corner and to the center portion 502. Each side
portion 504 is constructed to have a contoured surface 506 that
upon pressing a resilient tile blank will impart the desired shape
to the edge of the tile. For example, this contoured surface 506
may be a concave surface that will impart a convex edge to the
tile. Alternatively, the contoured surface 506 may be a flat angled
surface that imparts a beveled edge to the tile. The upper die
plate 500 may also be construed with a plurality of holes (not
shown) in the center portion 502 to allow for the passage of air
during pressing.
[0054] Also shown in FIG. 5, although not inherently part of the
upper die plate, is a knife 508. The knife 508 extends around the
entire perimeter of the upper die plate 500, and as shown in FIG. 4
comprises a beveled edge that provides a sharp edge at its tip
adjacent to the side portions 504 of the upper die plate 500.
[0055] FIG. 6A is a partial plan view of a die at a first operating
position according to one embodiment of the present invention. FIG.
6A illustrates the upper die plate 412 and the knife 416. It should
be appreciated that FIG. 6A is actually a cross-sectional view of
the upper die plate 412 and the knife 416 to illustrate the
curvature of the upper die plate 412 and the cutting edge of the
knife. Also shown are the resilient tile blank 422, the lower die
plate 414 and the scrap ejector plates 417 and their corresponding
springs 418. In this first operating position, the resilient tile
blank 422 has been loaded into the press and is ready to be cut and
molded.
[0056] FIG. 6B is a partial plan view of the die of FIG. 6A at a
second operating position according to one embodiment of the
present invention. In this second operating position, the upper die
plate 412 has been lowered using the hydraulic cylinder 408,
thereby cutting the perimeter portions 602 from the resilient tile
blank 422 and pressing the resilient floor tile blank 422 between
the upper die plate 412 and the lower die plate 414. The
compression forces imparted from the upper die plate 412 and the
stationary lower die plate 414 act to mold the resilient floor tile
blank 422 and impart the curvature 420 of the upper die plate 412
to the top edge of the resilient floor tile blank 422, thereby
forming a resilient floor tile. In essence, this process cuts and
molds the resilient floor tile blank concurrently.
[0057] When the upper die plate 412 is in the second operating
position, the scrap ejector plates 417 are depressed. After the
cutting and molding is complete, the upper die plate 412 is
returned to its first operating position to begin the cycle again
with a second resilient floor tile blank. Once the upper die plate
is lifted from this second operating position to return to its
first operating position, the scrap ejector plates 417 return to
their original position and hold the scrap or "frame" that has been
cut and separated from the resilient floor tile. As will be
discussed below, this enables removal and recycle of this scrape or
frame.
[0058] FIG. 7 is a process flow schematic of a process for making a
resilient floor tile according to one embodiment of the present
invention. The process 700 for cutting and molding a resilient
floor tile according to the present invention begins by using a
pallet of resilient floor tile blanks. A blank is a resilient floor
tile that has already been constructed but not cut into its final
dimensions. One of skill in the art will appreciate the various
methods for making resilient floor tile blanks and the various
compositions and constructions of such resilient floor tiles.
[0059] One preferred method for making a vinyl resilient floor tile
is described in U.S. patent application Ser. No. 09/765,713,
entitled "Coating Having Macroscopic Texture and Process for Making
Same," filed on Jan. 19, 2001, incorporated herein by reference in
its entirety. In this method, the vinyl tile is made by first
mixing a polyvinylchloride resin, plasticizer, pigments, and a high
level (.about.80%) of limestone (i.e., calcium carbonate) filler in
a blender held at 115-135.degree. F. The blended powder effluent is
then transferred to a continuous mixer held at 320-340.degree. F.
for fusion (i.e. chain entanglement) of the limestone-filled resin
into thermoplastic pieces of various sizes. The thermoplastic
pieces are next sent to calendering roll operations for partial
softening and re-fusion of the limestone-filled resin into the
shape of a continuous sheet having an exiting temperature of
250-270.degree. F. and a thickness of 50-200 mils. The continuous
sheet of tile base is then carried via a conveyor belt to a nip
station for lamination of a printed design using either 2 mil thick
printed polyvinylchloride film or 0.5 mil thick printed transfer
paper. The latter case involves transferring the ink of a printed
design, originally on a paper roll, to the tile base at the
lamination nip (the paper is subsequently removed with a re-wind
operation immediately following the lamination nip).
[0060] Next, the continuous sheet of tile base and laminated print
layer is conveyed to another nip for lamination of a cap film,
which is an .about.3 mil thick polyvinylchloride film designed to
protect the print layer. Both the cap film and print layer
applications rely upon the nip pressure and incoming substrate
temperature for lamination; the laminating rolls themselves are not
heated. For floors requiring periodic waxing, the polyvinylchloride
cap film forms the uppermost layer of the manufactured tile
construction (an end-user applied, sacrificial wax layer being the
uppermost layer in practice). However, for "no-wax" floors, a
thermosetting topcoat is applied as described below to the top of
the polyvinylchloride cap film during manufacture and forms a
surface with sufficient durability that the need for a sacrificial
wax layer is eliminated. Nevertheless, and regardless of its final
designation as a waxed or no-wax floor tile, the continuous sheet
of laminated tile base, print layer, and cap film is then
optionally mechanically embossed.
[0061] The traditional topcoat application process for no-wax tiles
involves the deposition and metering of a liquid film of
thermally-curable or radiation-curable resin onto the tile,
followed by subsequent curing of the resin to form a durable
thermoset topcoat. The traditionally preferred (but not exclusive)
coating application method involves the use of a curtain or roll
coater to apply and meter .about.3 mil of uncured UV-curable resin
to the cap film surface of the tile. The coated, but uncured, tiles
are then sent through a series of UV-processors containing UV lamps
to induce cross-linking of the thermosetting resin, in the case
where the coating is a radiation-curable coating. (Alternatively,
the tiles would be heated to induce the cross-linking in the case
where the coating is a thermally-curable coating.) The back coat is
typically applied and cured using a UV processor just prior to the
application of the top coat. A thermosetting urethane back coat is
also applied with a roll-coater to balance the curling stresses
imparted on the tile by the topcoat. Final processing of most
no-wax tile products then involves an annealing process to remove
processing stresses and to ensure dimensional stability.
[0062] It should be appreciated that application of the top coat
may be done before or after the process 700 for cutting and molding
the resilient floor tile. If the top coat material is a
thermoplastic material, the top coat could be applied to the tile
blank before being subject to the process 700 of cutting and
molding. However, if the top coat material is a thermoset material,
it is preferable to apply the top coat after the process 700 of
cutting and molding to avoid micro-cracks in the contoured edge
portion of the tile.
[0063] The pallet of resilient floor tile blanks are placed into a
destacker 702, which feeds the blanks one at a time to conveyor
belt 704 that passes through a pre-heated oven 706. The pre-heated
oven 706 conveys heat to the blanks using heat lamps, or any other
device capable of producing heat, as they travel through the
pre-heated oven 706 to sufficiently soften the blanks for
subsequent cutting and molding. One of skill in the art will
appreciate the degree of softness required based upon the
composition of the tile blank. For a vinyl or vinyl composition
tile blank, it is preferable to heat the blank to a temperature of
approximately 100-200.degree. F., more preferably to a temperature
of 125-135.degree. F. .+-.5.degree. F., and even more preferably to
a temperature of approximately 135.degree. F. .+-.2.degree. F.
Preferably, the pre-heated oven 706 has a length of approximately
10 feet, and the conveyor belt 704 travels through the pre-heated
over 706 at a speed of approximately 100' per minute to heat the
tile blank to this desired temperature.
[0064] The tile blanks are then picked-up from the pre-heated oven
conveyor belt 704 by an indexing chain-feed conveyor 708 that
carries each tile blank and positions it into a cut and mold press
710. In the cut and mold press 710, each tile blank is cut and
molded as described above in connection with FIG. 6 to form a
resilient floor tile having a contoured edge and a print layer that
extends over at least a portion of the contoured edge, which as
described above may include any contoured edge, including, for
example, a beveled edge or more preferably a convex edge.
[0065] After the cutting and molding, the indexing chain-feed
conveyor 708 ejects the finished resilient floor tile and the scrap
or frame portion out of the cut and mold press 710. Both the
finished resilient floor tile and the scrap or frame are then
conveyed to a counter/stacker 718. The resilient floor tile and the
scrap for frame are conveyed from the indexing chain-feed conveyor
708 to another conveyor belt 712, which is sufficiently separated
from the end of the indexing chain-feed conveyor 708 to allow the
scrap or frame to fall from the resilient floor tile into a drum
714 for recycle or disposal. The finished resilient floor tiles are
then conveyed to a counter/stacker 716 where they are assembled
into stacks, preferably stacks of 10 tiles and conveyed by conveyor
belt 718 to a pallet for distribution. As noted above, in the case
where a top coat is to be applied after the cutting and molding
process 700, the stacked and palletized resilient floor tiles are
conveyed to a coating line for application of the top coat. In
addition, the stacked and palletized resilient floor tiles may also
be subjected to an annealing process before distribution.
[0066] The invention having been described, the following example
is presented to illustrate, rather than to limit the scope of the
invention.
EXAMPLE 1
[0067] This Example illustrates one embodiment of the present
invention using a resilient floor tile comprising multiple layers.
A standard uncoated tile blank, specifically a DURASTONE tile from
Congoleum Corporation without a top coat was used. This tile has a
vinyl composition base and approximately 82% by weight inorganic
material and 18% by weight binder or total organic material
content. The tile was preheated in a 6' long conveyor oven having a
belt speed of 4.8 feet per minute and a set point temperature of
240.degree. F., which gave a tile temperature upon exiting the oven
of approximately 145.+-.5.degree. F. The tile blank was then fed to
the press at which point the tile temperature was approximately
140.degree. F. The press utilized a die constructed to impart a
convex shape to the top edge of the tile. The press was set to 20
tons and was closed for approximately 1-2 seconds. The press
temperature controller was set to 140.degree. F., which controls
the top plate of the press. The bottom plate of the press was kept
at room temperature. After pressing, the tile was coated with a
UV-curable coating. The final size of the tile was square having
the dimensions of 155/8''.times.155/8''. No cracks, such as micro
cracks, were observed on the convex edge or top surface.
[0068] In a similar trial, a UV-coated tile blank similar to the
one above but having a top coat was used. The processing was
similar to that described above except that the press was set to 8
tons, closed for 5 seconds, and the top plate was controlled at
220.degree. F. The resulting tile, however, exhibited micro cracks
around the convex or rounded edges. It is believed that the micro
cracks were the result of too much stress from the top coat.
EXAMPLE 2
[0069] This Example illustrates one embodiment of the present
invention using a resilient floor tile comprising only a base. Two
16''.times.16'' Congoleum CX SERIES commercial tile bases having a
CX-47 (earthen beige) pattern and a gauge thickness of 0.10'' were
adhered to each other using double-sided tape only for the purpose
of using a thicker tile to fit the die available for use in this
test. The CX SERIES tile base comprises vinyl acetate copolymer,
melamine, stabilizer, plasticizer, limestone, and TiO.sub.2, having
a total binder concentration of approximately 17% by weight. The
tile was preheated in a 6' long conveyor oven having a belt speed
of 4.8 feet per minute and a set point temperature of 240.degree.
F., which gave a tile temperature upon exiting the oven of
approximately 150.degree. F. The tile was then fed to the press at
which point the tile temperature was approximately 140.degree. F.
The press utilized a die constructed to impart a convex shape to
the top edge of the tile. The press was set to 30 tons and was
closed for approximately 2 seconds. The press temperature
controller was set to 140.degree. F., which controls the top plate
of the press. The bottom plate of the press was kept at room
temperature. The final size of the tile was square having the
dimensions of 151/4''.times.151/4''.
[0070] Various embodiments of the invention have been described.
The descriptions are intended to be illustrative of the present
invention. It will be apparent to one of skill in the art that
modifications may be made to the invention as described without
departing from the scope of the claims set out below. In
particular, it will be clear to those skilled in the art that the
present invention may be embodied in other specific forms,
structures, arrangements, proportions, and with other elements,
materials, and components, without departing from the spirit or
essential characteristics thereof. For example, it is to be
understood that although the invention has been described using as
an example a vinyl composition tile, any resilient floor tile may
be used. In addition, while the present invention is described as a
resilient floor tile, the tile may be used as a wall tile or for
other purposes. The presently disclosed embodiments are, therefore,
to be considered in all respects as illustrative and not
restrictive, the scope of the invention being indicated by the
appended claims, and not limited to the foregoing description.
* * * * *